Pail assembly for two materials

ABSTRACT

A pail assembly for transporting two materials is disclosed. The pail assembly includes a pail for containing one of the materials, a container with a closure for containing the second material, a lid assembly with a receptacle molded into the lid assembly for closing the pail and supporting the container for the second material and a lid for closing the receptacle on the lid assembly.

BACKGROUND OF THE INVENTION

Many products that are sold to consumers are sold in two parts, (Part Aand Part B) that are to be mixed by the consumer prior to use. Currentpackaging technology for two part reactive products that is utilized inindustry requires placement of a smaller Part B container of a hazardousproduct inside a larger, sturdy Part A pail to comply with US Departmentof Transportation (DOT) and Canadian Transportation of Dangerous Goods(TDG) regulatory requirements for shipping “Limited Quantity” ofhazardous materials. It is important that the two materials be keptseparated and the means of separation is able to withstand the type ofstresses common during transportation.

In some cases the Part B package may be a plastic container that isplaced inside of a bag and deposited on the Part A material inside ofthe Part A pail. This approach has the disadvantage that the Part Bpackage is not accessible unless the Part A pail is opened and manytimes the consumer will have to reach into the Part A material toretrieve the Part B material. Consumers have complained that thisprocedure is “messy.”

Another approach is described in U.S. Pat. No. 6,648,164 and comprises acradle and pail system. The cradle is shaped and sized to be containedwithin the upper portion of the interior of the pail. The cradle has aninterior molded surface forming a recess for storing one or moreseparately packaged containers such as a catalyst. The cradle is held inplace during transport by the crimped lid lugs of the lid. This approachrequires the use of a separate gasket to seal the cradle from thecontents of the pail. It suffers from the disadvantages that the Part Bcontainer is not accessible unless the Part A pail is opened. Further,the filling and assembly of the cradle and pail system require thepositioning of a gasket, the positioning of the cradle and the sealingof a lid over the cradle and gasket.

One of the optional aspects of the present invention is that itaddresses one or more of the problems discussed with conventionalapproaches for the packaging of two part reactive products.

Another optional aspect of the invention is that the Part B container iscarried on the exterior of the lid of the pail assembly.

Still another optional aspect of the invention is that the Part Bcontainer is accessible without the need to expose the Part A contentsof the pail to the environment.

SUMMARY OF THE INVENTION

Accordingly the present invention provides a pail assembly for packaginga Part A material and a Part B material including a pail with an openingfor containing the Part A material, a container for containing the PartB material, a lid assembly having a receptacle to contain and supportthe container separate from the Part A material; the lid assemblyserving as a closure for the pail containing the Part A material and alid for closing the container within the receptacle in the lid assembly.

The present invention also provides an integrally formed lid assemblyfor a pail having a first substantially planar portion defining an axisalong its center; an outer flange portion molded thereon and extendingfrom the substantially planar portion at an angle in a first direction.The outer flange portion is provided with a means of attachment to thepail. The lid assembly also includes a receptacle molded into the firstsubstantially planar portion and extending in an axial direction anddefining an opening to the receptacle. The lid assembly also includes aprotruding portion extending from the first substantially planar portionin a direction substantially opposite the direction of the receptacleand completely surrounding the opening of the receptacle. An externallid is provided to attach to the protruding portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1. is an exploded view of the pail assembly for two constituentsaccording to a first exemplary embodiment.

FIG. 2 is a cross section view of the lid assembly.

FIG. 3 is a cross section view of the assembled pail assembly

Reference will now be made in detail to exemplary embodiments of theinvention, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numbers are used in thedrawings and the description to refer to the same or like parts.

The pail assembly 1 according to the embodiment illustrated in FIG. 1may comprise a Part A Pail 10, a lid assembly 20 more specificallydescribed below, a Part B container 30, a Part B container lid 40 and asecond external lid 50. The pail assembly 1 may be made of materialsacceptable for the transportation of hazardous materials pursuant to theregulations promulgated by the Department of Transportation. Thesematerials may include plastic materials, steel, aluminum and othermetals as well as other materials set out in the Non-bulk PerformanceOriented Packaging Standards promulgated by the Department ofTransportation.

Part A pail 10 may be constructed in various shapes and may bepreferably cylindrical. Part A pail 10 may include a circular bottom 11,sidewalls 12, skirt 13 defining a circular horizontal surface 14 and anannular projection 15 having a bead 16 along its periphery and definingan opening 17. Part A pail 10 may be made of any suitable material andmay preferably be made of injection molded plastic material such aspolyethylene.

Lid assembly 20 is shown in greater detail in FIGS. 2 and 3. Lidassembly 20 may comprise an outer flange 21 which should be of anappropriate shape to engage the Part A pail 10. For example, if the PartA pail 10 is cylindrical then the outer flange 21 would be ring shaped.Outer flange 21 may be preferably tapered outwardly to enable multiplelid assemblies 20 to be stacked on top of each other. The outer flange21 also includes a circular concave groove 22 designed to engage bead 16to provide a seal between the lid assembly 20 and Part A pail 10.Alternately, the Lid assembly 20 may be provided with a plurality ofdetents to engage the bead 16 at the upper part of the side walls 12 ofthe Part A pail 10. The lid assembly 20 also may include a first innerflange 23, a second inner flange 24, and an annular projection 25 with abead 26 along the outer circumference of annular projection 25. The lidassembly 20 also may include a horizontal portion 27 inside of thecircumference of the annular projection 25. The lid assembly also mayinclude a cylindrical receptacle 28 projecting from the horizontalportion 27. The cylindrical receptacle may be integrally formed with thelid assembly 20. The cylindrical receptacle 28 is sized to receive thePart B container 30. A tear tab 29 may be molded into the flange 21 toallow consumers to easily remove the lid assembly 20 from the Part Apail 10. Preferably the cylindrical receptacle 28 would be tapered toallow for the stacking of multiple lid assemblies 20.

The Part B container 30 may be a smaller pail, a bottle, a bag or othersuitable container that can be sealed. In cases where the Part Bcontainer 30 is an injection molded plastic pail an adequate closure orlid such as Part B container lid 40 may be part of the pail assembly 1.It is desirable that when the Part B container 30 is closed with Part Bcontainer lid 40 and is inserted in the cylindrical receptacle 27, thetop of Part B container lid 40 is disposed below the plane defined bythe top of annular projection 25. Similarly the diameter of the Part Bcontainer lid 40 should be smaller than the diameter of the annularprojection 25 thereby allowing a user to easily lift the Part Bcontainer 30 from the lid assembly 20. Preferably the Part B container30 would be placed upright in the receptacle 28 to minimize leakage ofany part B material when the pail assembly 1 is in an upright position.

The pail assembly 1 also may include a second external lid 50 designedto engage the annular projection 25 and close the opening formed by theannular projection 25 thereby containing the Part B container 30securely in the cylindrical receptacle 28. The cylindrical receptacle 30can be accessed by removing the second external lid 50 while stillmaintaining the closure on the Part A materials provided by the lidassembly 20.

According to the invention, the Part A product will be filled into thePart A pail 10. Part A pail 10 will then be sealed with the lid assembly20. After placement of the lid assembly 20 on the Part A pail 10, thesmaller Part B container 30 will be filled with the Part B material andsealed with Part B container lid 40. The Part B container 30 will thenbe placed inside the receptacle 28 of the lid assembly 20. The secondexternal lid 50 will then be secured on the annular projection 25 toenclose the Part B Container 30 in the receptacle 28 of the lid assembly20. Part A pail 10, Part B container 20, Part B lid 40 and the secondexternal lid 50 may be of standard sizes that are commerciallyavailable.

According to the invention, to access the materials in the pail assembly1, the consumer will remove the second external lid 50 from the modifiedlid assembly 20 and remove the Part B container 30 from the receptacle28. The consumer will then remove the lid assembly 20 from the Part Apail 10 by pulling on the tear tab 29 on outer flange 21. The consumermay then pour the contents of the Part B container 20 into the Part Apail 10 and mix both parts together in Part A pail 10 to achieve thedesired product reaction for use.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the structure. While thegeometric description of the components of the pail assembly 1 aredescribed as cylindrical it is readily apparent that different shapesmay be used. Thus, it should be understood that the invention is notlimited to the examples discussed in the specification. Rather, thepresent invention is intended to cover modifications and variations.

1. A pail assembly for packaging a first product and a second productcomprising: a pail with an opening for containing the first product; acontainer for containing the second product; a lid assembly having areceptacle to contain and support said container separate from the firstproduct; said lid assembly having a closure member to enclose the firstproduct within the pail; and a lid for closing said container within thereceptacle in the lid assembly.
 2. The pail assembly of claim 1 wherethe pail assembly is made of injection molded plastic material.
 3. Thepail assembly of claim 1 wherein said lid assembly comprises: a) a firstsubstantially planar portion defining an axis along its center; b) anouter flange portion molded on said substantially planar portion andextending from said substantially planar portion at an angle in a firstdirection, said outer flange portion having means to attach to saidpail; c) a receptacle molded into the first substantially planar portionand extending along said axis in substantially the first direction anddefining an opening therein d) a protruding portion extending from thefirst substantially planar portion in a direction substantially oppositethe first direction and completely surrounding said opening in saidreceptacle
 4. The pail assembly of claim 1 wherein said container forcontaining the second product comprises one of: a) a second pail with alid; b) a sealed bag c) a bottle with a closure.
 5. The pail assembly ofclaim 1 wherein the pail and lid assembly are made of metal.
 6. The pailassembly of claim 1 wherein the pail and lid assembly are made ofinjection molded plastic.
 7. The pail assembly of claim 1 wherein saidreceptacle is tapered.
 8. The pail assembly of claim 3 wherein saidouter flange is flared outwardly.
 9. A pail assembly for packaging afirst material and a second material comprising: a) A pail forcontaining the first material; b) A container for containing the secondmaterial; c) means for closing the pail, said means for closing the pailincluding a receptacle to hold said container outside of said pail; andd) means for enclosing said container in said receptacle.
 10. The pailassembly of claim 9 wherein said means for closing the pail comprises alid assembly including a receptacle to hold said container and means forengaging said means for enclosing.
 11. The pail assembly of claim 10wherein the means for engaging comprises an annular projection with abead at the upper end thereof; and wherein said means for enclosing is alid with a plurality of detents to engage said bead.
 12. The pailassembly of claim 9 wherein the pail is made of metal.
 13. The pailassembly of claim 9 wherein the pail is made of plastic.
 14. The pailassembly of claim 9 wherein the means for closing the pail is made ofmetal.
 15. The pail assembly of claim 9 wherein the means for closingthe pail is made of plastic.
 16. A lid assembly for a pail comprising:an integrally formed member having: a) a first substantially planarportion defining an axis along its center; b) an outer flange portionmolded on said substantially planar portion and extending from saidsubstantially planar portion at an angle in a first direction, saidouter flange portion having means to attach to said pail; c) areceptacle molded into the first substantially planar portion andextending along said axis in substantially the first direction anddefining an opening therein d) a protruding portion extending from thefirst substantially planar portion in a direction substantially oppositethe first direction and completely surrounding said opening in saidreceptacle; and an external lid having means to attach said lid to saidprotruding portion.
 17. The lid assembly of claim 16 wherein the lidassembly is made of metal.
 18. The lid assembly of claim 16 wherein thelid assembly is made of plastic.
 19. The lid assembly of claim 16wherein said receptacle is in the shape of a tapered cylinder.
 20. Thelid assembly of claim 16 wherein said outer flange portion is flaredoutwardly.
 21. The lid assembly of claim 16 wherein said protrudingportion is an annular projection having a bead at the upper end thereof,and said external lid includes a plurality of detents to engage saidbead.
 22. A method of packaging two materials comprising the steps of:a) filling a pail with a first material; b) filling a container with asecond material; c) sealing the container; d) sealing the pail with alid assembly having a receptacle to receive said container on the outersurface of the receptacle; e) disposing the sealed container on saidreceptacle; and f) sealing the receptacle containing the container.